Module Construction

After previously helping to build a small club N scale layout with a steel tube frame and working on a Ho scale layout with a steel and hardwood frame I decided to go a more lightweight route for my fun sized On30 layout. As a proof of concept I have decided to build the three modules for Mt Rainbow yard first, they are 1200mm x 600mm and consist of foam board and what is called a plywood sandwich or laminated girder. Big thanks to this club for posting this page which has been an excellent guide for my design. http://www.bpmrc.org.uk/tech3.shtml

There are a few other pages on the net if you do a bit of a search which are of great value, after some thought I changed my mind about making the layout for display, the time and distance involved as well as money was more than I am willing to commit to and my enjoyment of the layout will come first but that is not to say that I will not take it on the road if time or conditions allow.
The foam board on the three yard modules will fit flush inside the outside frame to offer it some protection from impacts. The end sections that will butt up against each other are 18mm ply to add extra strength. I have used marine grade ply to build the modules because of its consistent quality and smoother finish. If you want to save a lot of time and have consistent straight lengths get your timber cut on a panel saw, I had mine cut at the hardware store where I brought the plywood and depending on the number of cuts or length they may even do it for free.

This is one of the end pieces of the module the 18mm ply is 130mm high and the thinner 7mm ply is 100 mm and the spacer blocks are 20mm thick by 89 mm wide pine cut to 100 mm lengths.

Once you get your timber cut you can have a bit of an assembly line going.

The first module with the outsides complete but not the internal bracing yet I also had to add more spacers to the long sides to stop flexing as you will have seen in the previous photo. The photo below shows a almost finished module.

My first attempt above and below of a corner module and I will tell you the two things wrong with it, the curve is out of shape and under a lot of stress. The other is the module is too narrow to allow the whole track curve to be on the module.

So I went back to the internet and graph pad and pencil and came up with a new module design for the corners which I then drew on the garage floor to aid in construction which my little helper is standing in.

I salvaged the end pieces of the crap corner modules and used them in the better design.

I placed the modules on the ground to drill the locating pins, I used 1 inch timber dowel for this purpose. I waited to build the last corner module until I did this so I could make the module fit the gap rater than have an out of shape layout or gaps between the other modules.

 Because it will be an operation layout I wanted the layout at a good height to view and work on so once again I searched the net looking for designs and examples and was quite surprised as to how little there was out there. The ones that were out there didn't quite suit me but gave me some ideas to use in my design. My design is also compact as the inner legs fold into the profile of the thicker legs, hinges are expensive and have a bit of play in them I decided to use bolts with a butterfly nut at the pivot point. The angle of the cut is 15 degrees

This is one of the three storage and transport racks under construction not only is Charlot hot but she is also freaking out due to the thunder storm about to arrive and cool down what has been a very hot day.

I put steerable rollers on one end of the storage units and fixed rollers on the other end and they seem to work well and are rated at 50kg each.

 

 The finished rack for two corner modules and the support legs, they will all fit vertically but it was the end of a long hot day and I just wanted to pack up.

The three storage racks together and as you can see by the bottom two modules on the right I have started to add the foam board.

I wanted to make the layout quick and easy to set up by one person, to facilitate this I put some 8 mm plugs into the top of the supports to secure the modules but allow movement for assembly or when you disassemble the layout. Not all the plugs are loose like this, every second set of legs have holes drilled into the end spacer blocks to provide a stable support for the layout.

First time on the trestle legs and no problems at all to my surprise.

Now the fun starts as I add foam to make the hills leading to the mine and to hide the staging yard.

Bells Creek bridge.

I have capped the end of the scenery foam with ply wood to make them more resistant to impacts when assembling the modules. I left gaps and cut the pieces to size.